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www.siemens.com/energy/connector-operations-manual

Document No: SRT-001

DigiTRON Electrical Flying Leads,Jumpers and Harness AssembliesSite Received Test Manual

http://www.siemens.com/energy/connector-operations-manual


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This page records the revision status of the entire document and its authorisation forissue. When a page or pages of the document are revised, the number of the pageaffected will be entered in the Page Affected/Remarks Column and a vertical marginline will appear against the latest amended text.

DigiTRON Electrical Flying Leads,Jumpers and Harness Assemblies

Site Received Test Manual

The contents of this document are confidential and must not be disclosed to any third partywithout prior consent in writing from Siemens Subsea Connectors a division of Siemens plc.

4 L.Belcher 09.06.2015 M.D.Bell 09.06.2015 Warning note with regard to lifting andPPE added at Section 6. CableAssemblies added to IR in section 11.

3 P.Westwell 29.4.2014 B.Leach 29.4.2014 New Cover design & complete documentreformat.

2 L.Belcher B.Leach 18.3.2014 Re-format, various text amendments,general updates

1 P.Westwell B.Leach 1.8.2013 First issue

By Date By IssueDate

Rev Compiled Checked Remarks / Pages Affected© Siemens Subsea Connectors, Page No.(a division of Siemens plc), Subsea ExcellenceCentre, Ulverston, Cumbria, LA12 9EE, England

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Contents

1. INTRODUCTION ..........................................................................................4

2. SCOPE ........................................................................................................4

3. ABBREVIATIONS ........................................................................................5

4. PURPOSE ...................................................................................................6

5. RESPONSIBILITIES ....................................................................................6

6. HEALTH & SAFETY ....................................................................................6

7. MANUAL HANDLING PACKING AND STORAGE .......................................7

8. VISUAL INSPECTION AND CHECKS .........................................................8

9. ELECTRICAL TESTING ............................................................................10

10. CONTINUITY TEST ...................................................................................1110.1 Fault Investigation ......................................................................................12

10.2 Continuity Test Results Sheet ....................................................................12

11. IR TEST .....................................................................................................1311.1 Fault Investigation ......................................................................................15

11.2 Insulation Resistance Test results sheet ....................................................16

12. INFORMATION AND NOTES / HEALTH & SAFETY FEEDBACK .............17

13. SIGN OFF SECTION .................................................................................17


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1. INTRODUCTION

This document is to provide the customer a simple test and check procedure toperform on receipt of supplied Electrical Flying Leads, Jumpers and Harnesses toconfirm identification, quality and operation..

2. SCOPE

This document defines the procedure and equipment required to carry out the SiteReceived Test on Electrical Flying Leads, Jumper and Harness. This is to determineno damage has taken place in transit and the EFL / JUMPER / HARNESS is fit to bedeployed. This test will also confirm basic electrical performance.

Any information, records or Health and Safety feedback that needs to be detailed,can be recorded in the punch list at the rear of the document..


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3. ABBREVIATIONS

A AmpereAC Alternating CurrentAssy AssemblyAPI American Petroleum InstituteAWG American Wire GaugeBOM Bill of Material°C Degree CelsiusCE Community EuropeanComms Communication SignalCP Cathodic ProtectionDC Direct CurrentDWG DrawingEFL Electrical Flying LeadsEMF Electrical Magnetic fieldFAT Factory Acceptance TestIR Insulation ResistanceISO International Organization for StandardizationITP Inspection Test PlanK KelvinLTC Long Term CoverM MetresMax. MaximumMFG ManufacturerMin. MinimumNo. NumberROV Remotely Operated VehicleSI Standard InternationalSRT Site Received TestSST Stainless SteelTBD To Be DefinedTSP Twisted Screened PairsUNS Unified Numbering System for Metals and AlloysV Volt


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4. PURPOSEThe purpose of this document is to ensure that the Site Received Test is performedwhere specified, on all AquaTRON oil-filled electrical jumpers and cable harnessassemblies. IR and Continuity tests will be performed along with a visual inspectionfor any damage pre and post test.

5. RESPONSIBILITIESIt is the operators’ responsibility to comply with this instruction and to ensure all testequipment is within calibration and report any problems to the Quality ControlInspector.

The operator shall also be responsible for completing the Test Results Sheets.All tests shall be carried out within a test cell, or specifically designed test area, whichshall be clearly identified. Controlled access to such areas shall be enforced.Care must be taken during handling, any damage to the hose or connectors canresult in schedule delays.

6. HEALTH & SAFETYManual Handling, Lifting and Carrying are known to be the largest contributors tooccupational ill-health. Ensure that mechanical handling aids are used wheneverpossible to avoid manual handling. Where manual handling is consideredappropriate for the task safe lifting guidelines must be followed, e.g. adopt correctposture, consider team lifting, employ safe lifting technique, etc.

WARNING: Please refer to product packaging for accurate lifting weight and ensurethe appropriate lifting equipment and PPE are used during handling operations.

Only competent persons are permitted to perform tasks without supervision, if indoubt ask. Good Housekeeping avoids Slips Trips and Falls, keep your area cleanand tidy. It is the operator’s responsibility to comply with current Company & regionalhealth and safety legislation.

Caution shall be exercised during assembly and testing to ensure that fittings andhydraulic/pneumatic equipment are properly installed. All high voltage testing shall beperformed by trained personnel using equipment that has been checked for safetywithin the last 12 months from the date of use. The operator shall be protected fromelectrocution by earth-screened enclosures that contain the H.V. hazard after everyH.V. test, an earth stick shall be used to verify that the conductors are discharged.For tests involving D.C. sufficient time must be allowed for the circuit to dischargebefore touching the conductors. The discharge period shall be at least equal to theperiod of charging.

In the event of a safety incident or any safety improvement suggestions pleasecontact the Health and Safety Department at [email protected] and/orcomplete and return the punch list in section 12.

Note – All receptacle’s (male pins) must be mated to its correct mating half before itis energised (this includes the correct Test, Dummy and Wet Mate Pair).

mailto:[email protected]


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7. MANUAL HANDLING PACKING AND STORAGE· Details on each of these sections, is explained in the IOM-001 manual.


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8. VISUAL INSPECTION AND CHECKS· Upon receipt of EFL / Jumper / Harness please handle in accordance with

procedures detailed in the IOM manual.

· Each page of this document contains a signature section to be completed bythe user.

· Visual inspection for damage to be completed by Siemens trained technician.

Please use check box as shown Pass ü Fail û

Check EFL / Jumper / harness and connectors are correct to parts ordered. If EFL is terminated with incorrect parts please stop test and inform Technical Dept............

Lay out EFL flat on a clean surface and check entire length for any visual damage orleaks. Some example images can be found below and on next page........................

Ensure hose is straight and check length against GA drawing....................................

Remove protective caps from connectors and check contact face / seal for Debris ordamage.......................................................................................................................

Check pins / sockets for damage.................................................................................

Inspect connector body for any impact damage, scratches..........................................

Re-install protective caps.............................................................................................

Check tagging and etching is to project requirements..................................................

Repackage and store in accordance with IOM manual.................................................

Any failure to this criterion must be recorded on the Information and Notes / Healthand Safety Feedback list at the back of this document and the technical departmentmust be informed.

Photos must be taken as evidence to help rectify any non-conformance.

Example images: To helpidentify hose damage,debris, defects andfading.

Check Hose surface fordamage such as cuts, rips,tears, leaks and deformity.

(Picture shows cut inhose)


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Check hose for discolouration and surface deformity.Faded hoses can beacceptable so long as they arein good condition with no leaksor cracks.

(Picture shows deformity)

Hose / Cable minimum bendradius must NOT be less thanstated, this could result indamage to the Hose / Cable

Minimum Bend Radius

Aquatron 50 Hose……..125 mmAquatron 75 Hose……..180 mm

Tronic 2 Core cable……273 mmTronic 4 Core cable……273 mmTronic 7 Core cable……300 mmTronic 12 Core cable…..400 mm

Make sure all contacts and mating facesare Clean and free from debris.

(Picture shows debris in contact)


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9. ELECTRICAL TESTING

ALL TESTS TO BE PERFORMED BY SIEMENS TRAINED OPERATIVESONLY.

General Equipment;-Ambient temperature / humidity recorderBarometer

Record atmospheric pressure, temperature & humidity (in accordance with theIEC 60060 standard) during electrical & function testing

Note: All calibrated equipment must have a current calibration certification atthe time of the test. Details must be recorded on the results Record Sheetsincluded in this document

The appropriate test connector must always be used to make electrical contactduring testing. UNDER NO CIRCUMSTANCES should a foreign object (such as ascrewdriver, test probe, or crocodile clip) be used as a test connection as this coulddamage the seals and insulation. Such actions will invalidate the warranty of theconnector / harness.


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10. CONTINUITY TESTEquipment Required9V Continuity TesterTest LeadsTest ConnectorWiring Diagram

Continuity Test

All equipment is functional and with calibration certificates..........................

Pre test Visual inspection of connectors and harness completed.................

Test connector and leads to be inspected for damage / debris......................

Inspect Test connector fixtures for damage / condition..................................

Visual inspection of hose / cable for damage or defects prior to testing......

If the above criterion is passed testing may begin.........................................

TEST PROCEDURE

· Attach the test leads to the 9V continuity tester.

· Touch the conductive ends of the test leads together. If the tester is in workingorder it will sound a "bleep".

· Attach one of the free ends of the test leads to one conductor, pin or socket(ensuring the plating is not damaged by the test lead).

· Attach the other test lead to the opposite end of the same conductor, pin orsocket.

· If there is a "bleep" continuity is acceptable and recorded as a PASS, If there isno bleep there is a break in continuity and must be recorded as a FAIL onResults sheet on next page.

· With the test lead attached to the first conductor the second test lead shall beattached to each of the remaining conductors in turn. Record Results. Thebleep must not sound during this test as this determines if a contact has beenshorted or cross connected and shall ensure each conductor is isolated fromthe remaining conductors. If the bleep does sound the item must be reworked

· When complete ensure protective caps are clean and free from debris, thesemust be re-fitted onto the connector immediately.

· Re-package and store in accordance with IOM-001 manual.


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10.1 FAULT INVESTIGATION(only complete if a fault is present)

If EFL / Jumper / Harness fails test:-

Check all connections are fully connected.......................................................

Remove all connections and inspect all contacts for damage or debris.......

While disconnected check all equipment is working and set up correctly....

If using a bench test board this must be fully checked for correctoperation.............................................................................................................

Re-connect all equipment and repeat tests......................................................

If there is still a fail please stop test and contact Technical Dept

10.2 CONTINUITY TEST RESULTS SHEET

Date..........................

Name of tester............................................

Project: Part No: Each pin to allothersEquipment used: Serial No:

Connector A - Pin Connector B - Pin PASS / FAIL PASS / FAIL

1 1

2 2

3 3

4 4

5 56 67 7

8 8

9 9

10 10

11 11

12 12

Pin……. to body Pin…… to body


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If the above criterion is passed testing may begin.............................

11. IR TESTEquipment Required:DC H.V tester (BM 21/MIT520 Megger or similar).Electrical test board with up to 12 connections. Test board specificationresistance to be greater than 10G Ohm. (Check prior to starting test)Suitable Test Connector where applicableWiring DiagramAll equipment to be inspected for functionality prior to starting testingcompleted

Insulation Resistance TestNote test voltage:Connector to Connector oil hose jumpers 4500V DCConnector to Sensor jumpers 50V DCCable Assemblies 1000V DC

All equipment is functional and with calibration certificates.............

Pre test Visual inspection of connectors and harness completed....

Test connector and leads to be inspected for damage debris...........

Inspect Test connector fixtures for damage / condition.....................

Visual inspection of hose / cable for damage or defects prior totesting.....................................................................................................


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Test connector to be mated to EFL, once mated place on a suitablebench for testing to begin.

Image to show standard Siemens test connectors

Procedure:

NOTE: On harnesses featuring nickel over braid, perform continuity test on the pin that hasthe over braid termination and the connector body to ensure no contact between them.

For harnesses incorporating Resistors:Perform insulation resistance test all pins to body/earth @ 50V DC through the appropriateconnector until the specified pass criteria is reached. Continue to run the test for a furtherminute (see note below) then record the result.

For harnesses NOT incorporating Resistors:Perform insulation resistance test all pins to body/earth @ *4500V DC (500V DC if screensincluded) through the appropriate connector until the specified pass criteria is reached.Continue to run the test for a further 1 minute (see note below) then record the result.

For harnesses with nickel over braid:Perform insulation resistance test on the pin that has the over braid termination @ 500VDC through the appropriate connector until the specified pass criteria is reached. Continueto run the test for a further 1 minute (see note below) then record the result.

NOTE: if the acceptance criteria is not reached within 10 minutes, contact theTechnical Dept.

IMPORTANT: IF THE CP WIRE IS CONNECTED TO THE SHELL, DO NOTINCLUDE IN TEST.

IR Test Acceptance:≥ 10GΩ @ 4500V DC on total wire length + test leads ≤ 50m (See note below).≥ 1GΩ @ 4500V DC on total wire length + test leads > 50m (See note below).>1MΩ @ 500V DC for screens + nickel over braid.No breakdown or flashover shall occur.

NOTE: The pass criteria used should be based on the accumulative length ofwire attached to the pin(s) plus the accumulative length of the test lead(s).

ROV DIVER STAB


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For tests involving DC sufficient time must be allowed for the circuit todischarge before touching the conductors. The discharge period shall be atleast equal to the period of charging.

· Record atmospheric pressure, temperature & humidity (in accordance with theIEC 60060 standard) during electrical & function testing. Record results intable.

· When complete ensure protective caps are clean and free from debris, thesemust be re-fitted onto the connector immediately.

Note:Insulation Resistance is dependent on a number of factors for example testvoltage, humidity (moisture content), temperature, time constant of sample,material properties, pressure, etc. A change in one of the above parameters willresult in a change in the IR reading.

In practice the control of these parameters is very difficult to achieve (i.e. IRreadings are sensitive to change) and this is recognised in internationalspecifications such as MIL-STD-883E, IEC60502, etc.

11.1 FAULT INVESTIGATION(only complete if a fault is present)

If EFL / Jumper / Harness fails test:

Check all connections are fully connected.......................................................

Remove all connections and inspect all contacts for damage ordebris...................................................................................................................

While disconnected check all equipment is working and set upcorrectly..............................................................................................................

If using a bench test board this must be fully checked for correctoperation ............................................................................................................

Re-connect all equipment and repeat tests......................................................

If there is still a fail please stop test and contact Technical Dept

FINAL CHECKMake sure this document has been fully completed and all results / informationrecorded in the correct section.


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11.2 INSULATION RESISTANCE TEST RESULTS SHEET

Project: Part No:Equipment used: Serial No:

Conductor ID (Pin-Pin) TEST VOLTAGERefer to Section 11 ALL CORES TO EARTH

1 Ω

Ω

2 Ω

3 Ω

4 Ω

5 Ω

6 Ω7 Ω

8 Ω

9 Ω

10 Ω

11 Ω

12 Ω

13 Ω

TEMP. (˚C) TESTER

HUMIDITY (%) DATE:


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12. INFORMATION AND NOTES / HEALTH & SAFETY FEEDBACKAll none conformances must be reported to the QC/QA department for investigationTake photos and contact Technical Dept.

Date Record Fail Action

13. SIGN OFF SECTIONPlease sign and date where indicated to confirm that each page of thisdocument has been read and complied with in full.

Name Signature Date

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DigiTRON Electrical Flying Leads, Jumpers and Harness ...w3.siemens.com/markets/global/en/oil-gas/PublishingImages/... · DigiTRON Electrical Flying Leads, Jumpers and Harness Assemblies